Valve cartridge with low point of contact for installation

ABSTRACT

A one-handle valve cartridge has a low point of contact for installing the valve cartridge in a valve body. A retention nut bears down on the low point of contact to secure the valve cartridge in the valve body.

RELATED APPLICATION

The present application is being filed as a non-provisional patentapplication claiming priority under 35 U.S.C. §119(e) from, and anyother benefit of, U.S. Provisional Patent Application No. 60/898,542filed on Jan. 31, 2007, the entire disclosure of which is hereinincorporated by reference.

FIELD

The invention relates generally to valve cartridges and, moreparticularly, to a valve cartridge having a low point of contact forinstalling the valve cartridge in a valve body.

BACKGROUND

Typically, for a plumbing fixture (e.g., a faucet, a tub spout, a showerhead), a valve body conveys water flowing from a main water source to adesired destination (e.g., a sink, a tub, a basin). The valve bodygenerally has two water inlet passages through which cold water and hotwater from the main water source can respectively flow. The valve bodyalso has a water outlet passage through which the cold water, the hotwater or a mixture of the cold and hot water can be discharged to anoutlet portion of the plumbing fixture (e.g., a spout). In a one-handleversion of the valve body, the valve body has a cavity for receiving avalve cartridge which allows a user to control the flow rate and thetemperature of the water flowing through the water inlet passages to thewater outlet passage using a single valve actuating mechanism.

One type of (conventional) valve cartridge is a structural assemblyincluding a housing in which two or more disks, plates or the like aredisposed. The disks are generally made of a hard material (e.g., ceramicor metal). At least one of the disks (i.e., a fixed disk) is fixedrelative to the housing. Another of the disks (i.e., a movable disk) isdisposed above the fixed disk and is movable relative to the fixed disk.The valve cartridge includes the actuating mechanism that is directly orindirectly connected at one end to the movable disk. Another end of theactuating mechanism extends through an opening in the housing formanipulation by a user. The end of the actuating mechanism extendingthrough the opening in the housing can be connected to a handle, knob orthe like to assist the user in operating the valve cartridge.

In a one-handle version of this type of valve cartridge for use in theone-handle version of the valve body, the fixed disk includes two inletopenings (i.e., a cold water inlet opening and a hot water inletopening) that substantially align with the water inlet passages of thevalve body when the valve cartridge is installed in the valve body.Furthermore, the fixed disk includes an outlet opening thatsubstantially aligns with the water outlet passage of the valve bodywhen the valve cartridge is installed in the valve body. The actuatingmechanism is connected to the movable disk via a coupling. The actuatingmechanism can be pivoted to cause translational movement of the movabledisk. The actuating mechanism can be rotated to cause angular movementof the movable disk.

In this manner, the movable disk can assume different positions relativeto the fixed disk. In particular, pivoting of the actuating mechanismchanges the flow rate of the water from zero to a maximum flow rate,whereas rotation of the actuating mechanism changes the temperature ofthe water. Accordingly, a one-handle actuating mechanism can controlboth the flow rate and the temperature of the water flowing through thevalve cartridge.

The valve cartridge also includes one or more seals for preventing waterfrom leaking out of the valve cartridge. The seals can be located, forexample, below, between and/or above the disks in the valve cartridge.When the valve cartridge is installed in the valve body, a retention nutis used to secure the valve cartridge in the valve body. The retentionnut engages an installation ledge of the housing of the valve cartridgesuch that the seals in the valve cartridge are compressed and, thus,apply a loading force to the components (including the disks) in thevalve cartridge. Accordingly, the fixed disk and the movable disk arekept in water tight contact after installation of the valve cartridge inthe valve body.

Typically, the conventional valve cartridge has the installation ledgeformed high on the housing of the valve cartridge, for example, near anupper opening of the valve cartridge. The high installation ledge formsthe point of contact between the retention nut and the valve cartridgewhen the valve cartridge is installed in the valve body.

As one example, a conventional valve cartridge 100 is illustrated inFIGS. 1A-1C and also illustrated in U.S. Pat. No. 7,063,106. As shown inFIGS. 1A-1B, the conventional valve cartridge 100 has several discretecomponents including a housing 102, a lower seal 104, a bottom member106, an upper seal 108, a fixed plate 110, a mobile plate 112, a carrier114, a rotatable support member 116, an operating lever 118 and a cover120. The housing 102 has a tubular shape for receiving the remainingcomponents of the valve cartridge 100.

The operating lever 118 is part of the actuating mechanism of the valvecartridge 100. The operating lever 118 is connected to the rotatablesupport member 116 via a pin 122. A lower surface of the rotatablesupport member 116 rests on an upper surface of the carrier 114. Therotatable support member 116 can rotate relative to the housing 102. Aportion of the operating lever 118 extends below the rotatable supportmember 116 and into the housing 102 which facilitates connecting theoperating lever 118 to the mobile plate 112, as described below. Aportion of the operating lever 118 extends above the rotatable supportmember 116 and out of the housing 102 which facilitates connecting theoperating lever 118 to an operating member (not shown), such as ahandle, a knob or the like.

The housing 102 has an internal shoulder 124 formed near a lower openingof the housing 102, wherein the internal shoulder 124 is shaped toreceive a correspondingly shaped portion of the bottom member 106. Thecover 120 has teeth 126 that snap fit into openings 128 formed near anupper opening of the housing 102. Accordingly, the lower opening of thehousing 102 is closed by the bottom member 106 and the upper opening ofthe housing 102 is closed by the cover 120, thereby securing thecomponents in the valve cartridge 100.

The fixed plate 110 has a pair of water inlet passages 130 and a wateroutlet passage 132. The fixed plate 110 is disposed above the bottommember 106. The mobile plate 112 is supported on top of the fixed plate110 and can slide on top of the fixed plate 110. The mobile plate 112includes a mixing chamber 134 for mixing cold and hot water flowing intothe valve cartridge 100 through the respective water inlet passages 130in the fixed plate 110. The mixed water then flows out of the valvecartridge 100 through the water outlet passage 132 in the fixed plate110.

The carrier 114 and the rotatable support member 116 function totranslate movement of the of the operating lever 118 into movement ofthe mobile plate 112. A lower portion of the carrier 114 engages anupper portion of the mobile plate 112. An upper portion of the carrier114 has a recess 136 for receiving a lower end 138 of the operatinglever 118, thereby connecting the operating lever 118 (which isconnected to the rotatable support member 116 via the pin 122) to thecarrier 114 and the mobile plate 112.

The lower seal 104 fits in a recess on a lower surface of the bottommember 106 and the upper seal 108 fits into a recess on an upper surfaceof the bottom member 106. The lower seal 104 forms a water tight sealbetween a valve body 140 in which the valve cartridge 100 is installedand the bottom member 106 (see FIG. 1C). The upper seal 108 forms awater tight seal between the bottom member 106 and the fixed plate 110(see FIG. 1B). The lower seal 104 and the upper seal 108 prevent waterfrom leaking out of the valve cartridge 100.

As shown in FIG. 1C, when the valve cartridge 100 is installed in thevalve body 140 of the plumbing fixture 142 (e.g., a faucet), a retentionnut 144 is used to secure the valve cartridge 100 in the valve body 140.The retention nut 144 engages an installation ledge 146 formed on thecover 120 of the housing 102 of the valve cartridge 100 such that theseals 104 and 108 in the valve cartridge 100 are compressed and, thus,apply a loading force to the components (including the fixed plate 110and the mobile plate 112) in the valve cartridge 100. Accordingly thefixed plate 110 and the mobile plate 112 are kept in water tight contactafter installation of the valve cartridge 100 in the valve body 140.

The position and the orientation of the mobile plate 112 relative to thefixed plate 110 are controlled by the operating lever 118 projecting outof the housing 102. In particular, the operating lever 118 can bepivoted within the rotatable support member 116 about the pin 122 andcan cause the rotatable support member 116 to rotate by rotation of theoperating lever 118. The operating member (not shown) can be connectedto the operating lever 118 to facilitate manipulation of the operatinglever 118 by the user. Accordingly, after the valve cartridge 100 isinstalled in the valve body 140, the user can manipulate the operatingmember which moves the operating lever 118 to change the position and/ororientation of the mobile plate 112 relative to the fixed plate 110,thereby controlling the flow rate and/or the temperature of the waterflowing through the valve cartridge 100 and out the plumbing fixture142, such as through a spout 148 (see FIG. 1C).

The installation ledge 146 is formed on the cover 120 so as to bedisposed high on the valve cartridge 100. As noted above, the retentionnut 144 engages the installation ledge 146 to secure the valve cartridge100 in the valve body 140. In this manner, the seals 104 and 108 arecompressed and a loading force resulting from the compression of theseals 104 and 108 is transmitted up to the components in the valvecartridge 100.

The high installation ledge 146 of the valve cartridge 100, however, hasseveral drawbacks. For example, the high installation ledge 146 resultsin less freedom in the design of plumbing fixtures for receiving thevalve cartridge 100. Furthermore, the high installation ledge 146 canresult in increased costs, as a height of sidewalls 150 of the valvebody 140 is often at least as high as the installation ledge 146.

Consequently, there is a need in the art for a valve cartridge having alow point of contact for installing the valve cartridge in a valve body.

SUMMARY

In view of the above, it is an exemplary aspect to provide a valvecartridge having a housing with a low point of contact formed on thehousing for installing the valve cartridge in a valve body.

It is another exemplary aspect to provide a valve cartridge having ahousing with at least one installation ledge formed on the housing,wherein a ratio of a height of a highest installation ledge of thehousing to a largest outer diameter of the housing is less than or equalto 0.53.

It is yet another exemplary aspect to provide a valve cartridge having ahousing with at least one installation ledge formed on the housing,wherein a ratio of a height of a highest installation ledge of thehousing to a largest outer diameter of the housing is less than or equalto 0.50.

It is still another exemplary aspect to provide a valve cartridge havinga housing with at least one installation ledge formed on the housing,wherein a ratio of a height of a highest installation ledge of thehousing to a largest outer diameter of the housing is less than or equalto 0.41.

It is another exemplary aspect to provide a valve cartridge having ahousing with at least one installation ledge formed on the housing,wherein a ratio of a height of a highest installation ledge of thehousing to a height of the housing is less than or equal to 0.49.

It is yet another exemplary aspect to provide a valve cartridge having ahousing with at least one installation ledge formed on the housing,wherein a ratio of a height of a highest installation ledge of thehousing to a height of the housing is less than or equal to 0.39.

It is still another exemplary aspect to provide a valve cartridge havinga housing with at least one installation ledge formed on the housing,wherein a ratio of a height of a highest installation ledge of thehousing to a height of a pin of the valve cartridge is less than orequal to 0.67.

It is another exemplary aspect to provide a valve cartridge having ahousing with at least one installation ledge formed on the housing,wherein a ratio of a height of a highest installation ledge of thehousing to a height of a pin of the valve cartridge is less than orequal to 0.55.

It is yet another exemplary aspect to provide a valve cartridge having ahousing with at least one installation ledge formed on the housing,wherein a highest installation ledge of the housing is below anactuating mechanism of the valve cartridge.

It is still another exemplary aspect to provide a valve cartridge havinga housing with at least one installation ledge formed on the housing,wherein a highest installation ledge of the housing is below anactuating mechanism of the valve cartridge and above a mixing chamber ofthe valve cartridge.

It is another exemplary aspect to provide a valve cartridge having ahousing with at least one installation ledge formed on the housing,wherein a highest installation ledge of the housing is below anactuating mechanism of the valve cartridge and above a fixed disk of thevalve cartridge. The highest installation ledge of the housing canextend over a portion of the fixed disk.

It is yet another exemplary aspect to provide a valve cartridge having ahousing with at least one installation ledge formed on the housing,wherein a height of a highest installation ledge of the housing isbetween 0.641 and 0.651 inches.

It is still another exemplary aspect to provide a valve cartridge havinga housing with at least one installation ledge formed on the housing,wherein a height of a highest installation ledge of the housing isbetween 0.486 and 0.494 inches.

BRIEF DESCRIPTION OF THE DRAWINGS

The above aspects and additional aspects, features and advantages willbecome readily apparent by describing in detail exemplary embodimentsthereof with reference to the attached drawings, wherein like referencenumerals denote like elements, and:

FIGS. 1A-1C show a conventional valve cartridge in which a point ofcontact between the valve cartridge and a retention nut for securing thevalve cartridge in a valve body is high. FIG. 1A shows the valvecartridge in unassembled form, as a cross-section. FIG. 1B shows thevalve cartridge of FIG. 1A in assembled form, as a cross-section. FIG.1C shows the valve cartridge of FIG. 1B after installation in a plumbingfixture, as a cross-section.

FIG. 2 is a perspective exploded view of a valve cartridge, according toan exemplary embodiment.

FIGS. 3A-3E show an exemplary housing used in the exemplary valvecartridge of FIG. 2. FIG. 3A is a perspective view of the housing. FIG.3B is a side elevational view of the housing. FIG. 3C is across-sectional view of the housing shown in FIG. 10A, along line A-A.FIG. 3D is a cross-sectional view of the housing shown in FIG. 10A,along line B-B. FIG. 3E is a cross-sectional view of the housing of FIG.3C, along line C-C.

FIG. 4 is a perspective view of an exemplary ball-stem of the exemplaryvalve cartridge of FIG. 2.

FIGS. 5A-5C show an exemplary spring used in the exemplary valvecartridge of FIG. 2. FIG. 5A is a perspective view of the spring. FIG.5B is a plan view of the spring. FIG. 5C is a side elevational view ofthe spring.

FIGS. 6A-6D show an exemplary bushing used in the exemplary valvecartridge of FIG. 2. FIG. 6A is a perspective view of the bushing. FIG.6B is a side elevational view of the bushing. FIG. 6C is a bottom viewof the bushing. FIG. 6D is a cross-sectional view of the bushing of FIG.6C, along line A-A.

FIGS. 7A-7D show an exemplary flow plate used in the exemplary valvecartridge of FIG. 2. FIG. 7A is a perspective view of the flow plate.FIG. 7B is a plan view of the flow plate. FIG. 7C is a cross-sectionalview of the flow plate of FIG. 7B, along line A-A. FIG. 7D is across-sectional view of the flow plate of FIG. 7B, along line B-B.

FIG. 8 is a perspective view of an exemplary manifold of the exemplaryvalve cartridge of FIG. 2.

FIGS. 9A-9B show an exemplary base seal used in the exemplary valvecartridge of FIG. 2. FIG. 9A is a top perspective view of the base seal.FIG. 9B is a bottom perspective view of the base seal.

FIGS. 10A-10C show the exemplary valve cartridge of FIG. 2 in assembledform. FIG. 10A is a plan view of the valve cartridge in assembled form.FIG. 10B is a cross-sectional view of the valve cartridge of FIG. 10A,along line A-A. FIG. 10C is a cross-sectional view of the valvecartridge of FIG. 10A, along line B-B.

FIG. 11 is a mirror image of a cross-sectional view (along line B-B inFIG. 10A) of the exemplary valve cartridge of FIG. 2 after installationin a plumbing fixture.

FIG. 12 is a perspective exploded view of a valve cartridge, accordingto another exemplary embodiment.

FIGS. 13A-13C show an exemplary upper housing used in the exemplaryvalve cartridge of FIG. 12. FIG. 13A is a perspective view of the upperhousing. FIG. 13B is a side elevational view of the upper housing. FIG.13C is a cross-sectional view of the upper housing of FIG. 13B, alongline A-A.

FIG. 14 is a perspective view of an exemplary ball-stem of the exemplaryvalve cartridge of FIG. 12.

FIGS. 15A-15C show an exemplary spring used in the exemplary valvecartridge of FIG. 12. FIG. 15A is a perspective view of the spring. FIG.15B is a plan view of the spring. FIG. 15C is a cross-sectional view ofthe spring of FIG. 15B, along line A-A.

FIGS. 16A-16C show an exemplary bushing used in the exemplary valvecartridge of FIG. 12. FIG. 16A is a side elevational view of thebushing. FIG. 16B is a cross-sectional view of the bushing of FIG. 16Aalong line A-A. FIG. 16C is a plan view of the bushing.

FIGS. 17A-17D show an exemplary carrier used in the exemplary valvecartridge of FIG. 12. FIG. 17A is a perspective view of the carrier.FIG. 17B is a plan view of the carrier. FIG. 17C is a bottom view of thecarrier. FIG. 17D is a side elevational view of the carrier.

FIGS. 18A-18C show an exemplary movable disk used in the exemplary valvecartridge of FIG. 12. FIG. 18A is a plan view of the movable disk. FIG.18B is a cross-sectional view of the movable disk of FIG. 18A, alongline A-A. FIG. 18C is a bottom view of the movable disk.

FIGS. 19A-19D show an exemplary fixed disk used in the exemplary valvecartridge of FIG. 12. FIG. 19A is a top perspective view of the fixeddisk. FIG. 19B is a bottom perspective view of the fixed disk. FIG. 19Cis a plan view of the fixed disk. FIG. 19D is a bottom view of the fixeddisk.

FIGS. 20A-20B show an exemplary base seal used in the exemplary valvecartridge of FIG. 12. FIG. 20A is a top perspective view of the baseseal. FIG. 20B is a plan view of the base seal.

FIGS. 21A-21D show an exemplary lower housing used in the exemplaryvalve cartridge of FIG. 12. FIG. 21A is a top perspective view of thelower housing. FIG. 21B is a bottom perspective view of the lowerhousing. FIG. 21C is a plan view of the lower housing. FIG. 21D is abottom view of the lower housing.

FIGS. 22A-22C show the exemplary valve cartridge of FIG. 12 in assembledform. FIG. 22A is a plan view of the valve cartridge in assembled form.FIG. 22B is a cross-sectional view of the valve cartridge of FIG. 22A,along line A-A. FIG. 22C is a cross-sectional view of the valvecartridge of FIG. 22A, along line B-B.

DETAILED DESCRIPTION

While the general inventive concept is susceptible of embodiment in manydifferent forms, there are shown in the drawings and will be describedherein in detail specific embodiments thereof with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the general inventive concept. Accordingly, thegeneral inventive concept is not intended to be limited to the specificembodiments illustrated herein.

A one-handle valve cartridge 200, according to an exemplary embodiment,has a low point of contact for securing the valve cartridge 200 in avalve body 240. Accordingly, the valve cartridge 200 may overcome thedrawbacks of conventional valve cartridges having a high point ofcontact.

As shown in FIGS. 2 and 10A-10C, the exemplary valve cartridge 200 hasseveral discrete components including a housing 202, a ball-stem 204, apin 206, a spring 208, a bushing 210, a flow plate 212, a manifold 214and a base seal 216. The flow plate 212 and/or the manifold 214 can bemade of a hard material. For example, the flow plate 212 and/or themanifold 214 can be made of stainless steel. The housing 202, forexample, can be made of plastic or metal.

As shown in FIGS. 3A-3E, the housing 202 has a domed portion 218 and acylindrical portion 220. A cavity 222 is formed in the housing 202 forreceiving the remaining components of the valve cartridge 200. Thecavity 222 extends inside the domed portion 218 and the cylindricalportion 220 of the housing 202. The cylindrical portion 220 of thehousing 202 includes a lower opening 224 through which the componentscan be inserted into the housing 202. The domed portion 218 of thehousing 202 includes an upper opening 226 through which a stem portion228 of the ball-stem 204 extends. The cavity 222 in the housing 202 iswider near the lower opening 224 than near the upper opening 226. Aportion of the cavity 222 near the upper opening 226 of the housing 202receives a ball portion 230 of the ball-stem 204. Accordingly, a firstinner surface 232 of the portion of the cavity 222 near the upperopening 226 has a shape that substantially conforms to a shape of theball portion 230 of the ball-stem 204 (see FIGS. 10B-10C and 11).

A portion of the cavity 222 near the lower opening 224 of the housing202 receives the bushing 210, the flow plate 212, the manifold 214 andthe base seal 216. A diameter of the cavity 222 near the lower opening224 is substantially the same as a diameter of the base seal 216, themanifold 214 and a flat annular portion 234 of the bushing 210, suchthat only a small gap is present between these components and thehousing 202 when the components are received in the housing 202.

A portion of the housing 202 where the domed portion 218 meets thecylindrical portion 220 forms an installation ledge 236 on an outersurface of the housing 202. The installation ledge 236 is substantiallybelow the upper opening 226 of the housing 202. A retention nut 238engages the installation ledge 236 to secure the valve cartridge 200 ina valve body 240 (see FIG. 11). Furthermore, the housing 202 has one ormore keys 242 that each engage a complementary-shaped recess (not shown)in the valve body 240 to prevent rotation of the housing 202 relative tothe valve body 240 after the valve cartridge 200 is installed. The oneor more keys 242 can have a lobular shape. The housing 202 also includesa pair of slots 244 formed on opposing sides of the housing 202 thatinterface with distal ends of the pin 206 to function astemperature-limit stops, as described below.

As shown in FIG. 4, the ball-stem 204 is the actuating mechanism for thevalve cartridge 200. The ball-stem 204 includes the ball portion 230 andthe stem portion 228. The ball portion 230 and the stem portion 228 canbe discrete components or can be formed integrally. The ball portion 230includes a projection 246 extending from a side of the ball portion 230that is opposite a side of the ball portion 230 from which the stemportion 228 extends. The projection 246 acts as a coupling device forconnecting the ball-stem 204 to the flow plate 212, as described below.The ball portion 230 and the projection 246 can be discrete componentsor can be formed integrally.

A bore 248 is formed through a center of the ball portion 230 of theball-stem 204. The bore 248 is orthogonal to the stem portion 228 of theball-stem 204. After the ball-stem 204 is inserted into the cavity 222of the housing 202, the pin 206 can be inserted through one of the slots244 in the housing 202 and into the bore 248 of the ball-stem 204. Inthis manner, the pin 206 retains the ball-stem 204 in the housing 202.

As shown in FIGS. 5A-5C, the spring 208 has an annular shape with acentral opening 250. The spring 208 is disposed below the ball portion230 of the ball-stem 204 in the housing 202 (see FIGS. 10B-10C). Thespring 208 is connected to a second inner surface 252 of the housing 202(e.g., by or through threading, friction fitting, snap fitting,welding), such that the spring 208 also retains the ball-stem 204 in thehousing 202. The spring 208 has a plurality of notches 254 formed on anouter periphery 256 of the spring 208. The notches 254 engagecorresponding tabs 258 formed on the second inner surface 252 of thehousing 202 (see FIG. 3C), thereby securing the spring 208 within thehousing 202 below the ball-stem 204.

The projection 246 of the ball-stem 204 extends through the centralopening 250 in the spring 208. Some of the ball portion 230 of theball-stem 204 can also extend through the central opening 250 in thespring 208. The spring includes a plurality of elastic flanges 260surrounding the central opening 250. The elastic flanges 260 of thespring 208 contact the ball portion 230 of the ball-stem 204 and urgethe ball portion 230 of the ball-stem 204 against thecomplementary-shaped first inner surface 232 of the housing 202.

As shown in FIGS. 6A-6D, the bushing 210 includes the flat annularportion 234 and a raised annular portion 262. A diameter of the flatannular portion 234 is greater than a diameter of the raised annularportion 262. The bushing 210 is disposed below and can be spaced apartfrom the spring 208 in the cavity 222 of the housing 202 (see FIGS.10B-10C). An upper surface 264 of the flat annular portion 234 of thebushing 210 contacts a third inner surface 266 of the housing 202, whichis located below the installation ledge 236 (see FIGS. 3C-3D and10B-10C). A lower surface 268 of the flat annular portion 234 of thebushing 210 rests on an upper surface 270 of a flat portion 272 of theflow plate 212. Additionally, the raised annular portion 262 of thebushing 210 extends into a portion of the cavity 222 of the housing 202immediately above the installation ledge 236. The raised annular portion262 of the bushing 210 is sized to fit closely in that portion of thecavity 222 of the housing 202 receiving the raised annular portion 262of the bushing 210. Accordingly, the bushing 210 provides a supportsurface between the housing 202 and the flow plate 212.

The bushing 210 has an opening 274 that extends through the flat annularportion 234 and the raised annular portion 262 of the bushing 210. Araised portion 276 of the flow plate 212 extends into the opening 274 ofthe bushing 210. The raised portion 276 of the flow plate 212 forms amixing chamber 278. A portion of the opening 274 of the bushing 210 hasan inner surface shaped to conform to a shape of the raised portion 276of the flow plate 212 (see FIGS. 6C-6D). Additionally, a coupling recess280 is formed on the raised portion 276 of the flow plate 212 (see FIGS.7A-7D). After the flow plate 212 is installed in the valve cartridge200, the coupling recess 280 is positioned within the opening 274 of thebushing 210 and surrounded by the raised annular portion 262 of thebushing 210 (see FIGS. 10B-10C).

The coupling recess 280 of the flow plate 212 receives the projection246 of the ball-stem 204, thereby connecting the actuating mechanism(i.e., the ball-stem 204) and the flow plate 212. The projection 246 ofthe ball-stem 204 can have four sides that contact four correspondingsides of the coupling recess 280. The projection 246 of the ball-stem204 does not contact a bottom surface of the coupling recess 280. Itwill be appreciated that notwithstanding the exemplary embodimentsdescribed herein, the ball-stem 204 can be connected to the flow plate212 in any suitable manner that allows the ball-stem 204 to imparttranslational and angular movement to the flow plate 212.

As shown in FIGS. 7A-7D, the flow plate 212 is a valve member formed asa plate, disk or the like that is movable relative to the housing 202.The flow plate 212 includes the flat portion 272 and the raised portion276. The flat portion 272 of the flow plate 212 forms a sealing surfacethat can cover and uncover water inlet apertures 282 and 284 in themanifold 214 to allow only cold water, only hot water or both cold andhot water to flow through the manifold 214. The water flowing throughthe water inlet apertures 282 and 284 in the manifold 214 enters themixing chamber 278 (i.e., a cavity formed under the raised portion 276of the flow plate 212) where the cold and hot water mixes prior to beingdischarged through a water outlet aperture 286 in the manifold 214.Furthermore, as noted above, the flow plate 212 also includes thecoupling recess 280, which is formed on the raised portion 276 of theflow plate 212.

As shown in FIG. 8, the manifold 214 is a valve member formed as aplate, disk or the like that is fixed relative to the housing 202. Themanifold 214 includes one or more projections 288 formed on a periphery290 of the manifold 214, wherein each of the projections 288 fits insidean internal cavity 292 of one of the keys 242 of the housing 202 (seeFIGS. 3A and 3E). The projections 288 fix the manifold 214 relative tothe housing 202, thereby preventing rotation of the manifold 214 withinthe housing 202.

The manifold 214 includes the water inlet apertures 282 and 284, whichcorrespond to a cold water inlet aperture and a hot water inletaperture, respectively. The manifold 214 also includes the water outletaperture 286 through which cold water flowing through the cold waterinlet aperture 282, hot water flowing through the hot water inletaperture 284 or a mixture of the cold and hot water can flow to a wateroutlet passage (not shown) of the valve body 240.

As shown in FIGS. 9A-9B, the base seal 216 is a sealing member formed ofan elastic material (e.g., rubber). The base seal 216 includes one ormore projections 294 formed on a periphery 296 of the base seal 216,wherein each of the projections 294 fits inside the internal cavity 292of one of the keys 242 of the housing 202. The projections 294 fix thebase seal 216 relative to the housing 202, thereby preventing rotationof the base seal 216 within the housing 202. The base seal 216 alsoincludes one or more tabs 298 formed on the periphery 296 of the baseseal 216, wherein the one or more tabs 298 are deformable to fit in andextend through a corresponding one or more openings 300 formed in thehousing 202 to secure the base seal 216 in the housing 202. The one ormore tabs 298 can have different sizes.

Like the manifold 214, the base seal 216 has a cold water inlet aperture302, a hot water inlet aperture 304 and a water outlet aperture 306. Thecold water inlet aperture 302 and the hot water inlet aperture 304 ofthe base seal 216 each have walls 308 that slope from near a lowersurface 310 of the base seal 216 to near an upper surface 312 of thebase seal 216 to improve the flow of water through the base seal 216 andinto the valve cartridge 200. The water outlet aperture 306 of the baseseal 216 has walls 314 that slope from near the upper surface 312 of thebase seal 216 to near the lower surface 310 of the base seal 216 toimprove the flow of water through the base seal 216 and out of the valvecartridge 200. It is important that the apertures 282, 284 and 286 inthe manifold 214 are aligned with the apertures 302, 304 and 306 in thebase seal 216 when the valve cartridge 200 is assembled. Accordingly,the projections 288 on the manifold 214 and the projections 294 on thebase seal 216 insure that the manifold 214 and the base seal 216 fitinto the housing 202 in only one orientation, wherein the apertures 282,284 and 286 in the manifold 214 are aligned with the apertures 302, 304and 306 in the base seal 216 in this orientation.

A ridge 316 surrounds the apertures 302, 304 and 306 in the base seal216 on the upper surface 312 of the base seal 216 (see FIG. 9A).Similarly, a ridge 318 surrounds the apertures 302, 304 and 306 in thebase seal 216 on the lower surface 310 of the base seal 216 (see FIG.9B). The ridges 316 and 318 of the base seal 216 are compressed when thevalve cartridge 200 is installed in the valve body 240 (see FIGS.10B-10C and 11 which show the ridges 316 and 318 overlapped with thecompressing structure for purposes of illustration only). In particular,as the retention nut 238 is tightened down oil the installation ledge236 of the housing 202, the ridge 316 is compressed between the manifold214 of the valve cartridge 200 and the base seal 216, while the ridge318 is compressed between the base seal 216 and a seating surface 320 ofthe valve body 240 (see FIG. 11). It should be noted that although theprojections 288 of the manifold 214 prevent the manifold 214 fromrotating within the housing 202, the projections 288 nonetheless allowthe manifold 214 to move axially within the housing 202. In this manner,the compression of the ridges 316 and 318 of the base seal 216 exerts aloading force on the flow plate 212 and the manifold 214. Accordingly,the flow plate 212 and the manifold 214 are kept in water-tightengagement with one another, after installation of the valve cartridge200.

The retention nut 238 is a hollow nut that engages sidewalls 322 of thevalve body 240 to secure the valve cartridge 200 in the valve body 240(see FIG. 11). For example, the retention nut 238 can have externalthreads for engaging complementary threads on the sidewalls 322. Aninner surface of the retention nut 238 is shaped to conformsubstantially to a shape of the domed portion 218 of the housing 202.The installation ledge 236, however, is the only portion of the housing202 that the retention nut 238 contacts during installation of the valvecartridge 200 in the valve body 240.

Additionally, the retention nut 238 and/or the valve body 240 can havestructural features that prevent an excessive amount of torque frombeing transferred to the valve cartridge 200. For example, the retentionnut 238 includes an annular flange 326 that bottoms out on a surface 328of the valve body 240 to prevent excessive tightening of the retentionnut 238 (see FIG. 11). Accordingly, the annular flange 326 functions tolimit the maximum amount of torque that can be transferred from theretention nut 238 to the valve cartridge 200.

The position and the orientation of the flow plate 212 relative to themanifold 214 are controlled by the stem portion 228 of the ball-stem 204projecting out of the housing 202 through the upper opening 226. Forexample, pivoting the stem portion 228 of the ball-stem 204 about thepin 206 changes the position of the flow plate 212 relative to themanifold 214, which changes the flow rate of the water. Rotating thestem portion 228 of the ball-stem 204 changes the orientation of theflow plate 212 relative to the manifold 214, which changes thetemperature of the water.

An operating member 330 such as a handle, knob or the like (see FIG. 11)can be connected to the stem portion 224 of the ball-stem 204 tofacilitate manipulation of the stem portion 228 by the user.Accordingly, after the valve cartridge 200 is installed in the valvebody 240, the user can manipulate the operating member 330 which movesthe stem portion 228 of the ball-stem 204 to change the position and/ororientation of the flow plate 212 relative to the manifold 214, therebycontrolling the flow rate and temperature of the water flowing throughthe valve cartridge 200 and out a plumbing fixture 332, such as througha spout (not shown) of the plumbing fixture 332 (see FIG. 11).

Pivoting of the stem portion 228 of the ball-stem 204 about the pin 206can be limited by the stem portion 228 contacting opposing surfaces ofthe upper opening 226 of the housing 202. Thus, the stem portion 224 ofthe ball-stem 204 contacts a first surface 334 of the upper opening 226of the housing 202 when the valve cartridge 200 is in a fully closedposition corresponding to a flow rate of zero (see FIG. 10C). The stemportion 228 of the ball-stem 204 contacts a second surface 336 of theupper opening 226 of the housing 202 when the valve cartridge 200 is ina fully open position corresponding to a maximum flow rate.

Rotation of the stem portion 228 of the ball-stem 204 can be limited bythe distal ends of the pin 206 contacting end portions 338 of the slots244 (see FIGS. 2, 3A-3B and 10A). Accordingly, the length of the slots244, which function as temperature limit stops, define the range oftemperatures for which the valve cartridge 200 can deliver the water.

The valve cartridge 200 has a low point of contact (i.e., theinstallation ledge 236 formed on the housing 202) on which the retentionnut 238 bears down. The installation ledge 236 is a circular ledge thatextends around the housing 202 where the domed portion 218 of thehousing 202 meets the cylindrical portion 220 of the housing 202. Theinstallation ledge 236 is the highest point on the housing 202 thatcontacts the retention nut 238.

In an exemplary embodiment of the exemplary valve cartridge 200, one ormore installation ledges (e.g., the installation ledge 236) are formedon the housing 202 of the valve cartridge 200. The highest of theinstallation ledges is a low point of contact on the housing 202 forinstalling the valve cartridge 200 in the valve body 240.

A ratio R₁ of a height h₁ of the highest installation ledge on thehousing 202 to a largest outer diameter d of the housing 202 is lessthan or equal to 0.50 (see FIG. 10B), which can be expressed ash₁/d≦0.50. In another exemplary embodiment of the exemplary valvecartridge 200, the ratio R₁ of the height h₁ to the largest outerdiameter d is less than or equal to 0.41 (see FIG. 10B). In stillanother exemplary embodiment, the ratio R₁ of the height h₁ to thelargest outer diameter d is approximately equal to 0.40.

According to still another exemplary embodiment of the exemplary valvecartridge 200, a ratio R₂ of the height h₁ to a height h₂ of the housing202 is less than or equal to 0.39 (see FIG. 10B), which can be expressedas h₁/h₂≦0.39. In another exemplary embodiment, the ratio R₂ of theheight h₁ to the height h₂ is approximately equal to 0.38. In stillanother exemplary embodiment, the ratio R₂ of the height h₁ to theheight h₂ is approximately equal to 0.36.

According to yet another exemplary embodiment of the exemplary valvecartridge 200, a ratio R₃ of the height h₁ to a height h₃ of the pin 206(e.g., from a bottom of the housing 202 to a centerline of the pin 206)is less than or equal to 0.55 (see FIG. 10B), which can be expressed ash₁/h₃≦0.55. In another exemplary embodiment, ratio R₃ of the height h₁to the height h₃ is approximately equal to 0.54. In still anotherexemplary embodiment, ratio R₃ of the height h₁ to the height h₃ isapproximately equal to 0.50.

According to another exemplary embodiment of the exemplary valvecartridge 200, the highest installation ledge on the housing 202 isbelow an actuating mechanism (e.g., the ball-stern 204) of the valvecartridge 200 (see FIG. 10B). In still another exemplary embodiment ofthe exemplary valve cartridge 200, the highest installation ledge on thehousing 202 is below the actuating mechanism and above a mixing chamber(e.g., the mixing chamber 278) of the valve cartridge 200. In yetanother exemplary embodiment of the exemplary valve cartridge 200, thehighest installation ledge on the housing 202 is below the actuatingmechanism and above a fixed disk (e.g., the manifold 214) of the valvecartridge 200.

According to an exemplary embodiment of the exemplary valve cartridge200, the height h₁ of the highest installation ledge on the housing 202is between 0.486 and 0.494 inches. In one exemplary embodiment, theheight h₁ of the highest installation ledge on the housing 202 isapproximately equal to 0.490 inches.

According to another exemplary embodiment of the exemplary valvecartridge 200, the height h₂ of the housing 202 is between 1.377 and1.385 inches. In another exemplary embodiment, the height h₂ of thehousing 202 is between 1.277 and 1.285 inches. In one exemplaryembodiment, the height h₂ of the housing 202 is approximately equal to1.381 inches. In another exemplary embodiment, the height h₂ of thehousing 202 is approximately equal to 1.281 inches.

According to still another exemplary embodiment of the exemplary valvecartridge 200, the height h₃ of the pin 206 is between 0.977 and 0.994inches. In another exemplary embodiment, the height h₃ of the pin 206 isbetween 0.902 and 0.919 inches. In one exemplary embodiment, the heighth₃ of the pin 206 is approximately equal to 0.986 inches. In anotherexemplary embodiment, the height h₃ of the pin 206 is approximatelyequal to 0.911 inches.

According to yet another exemplary embodiment of the exemplary valvecartridge 200, the outer diameter d of the housing 202 is between 1.216and 1.224 inches. In one exemplary embodiment, the outer diameter d ofthe housing 202 is approximately equal to 1.220 inches.

As illustrated by way of the exemplary embodiments described herein, theinstallation ledge 236 (as a highest installation ledge on the housing202) is a low point of contact on the housing 202 on which the retentionnut 238 can bear down during installation of the valve cartridge 200 inthe valve body 240. Accordingly, the valve cartridge 200 has a compactstructure that provides increased flexibility in the design of plumbingfixtures (e.g., the plumbing fixture 332 shown in FIG. 11) that willaccommodate the valve cartridge 200. Furthermore, the low installationledge 236 allows less material to be used in forming the valve body 240,since sidewalls 322 of the valve body 240 can be made shorter (see FIG.11). As a result, the low installation ledge 236 provides a costsavings.

A one-handle valve cartridge 400, according to another exemplaryembodiment, has a low point of contact for securing the valve cartridge400 in a valve body (e.g., the exemplary valve body 240 shown in FIG.11). Accordingly, the valve cartridge 400 may overcome the drawbacks ofconventional valve cartridges having a high point of contact.

As shown in FIGS. 12 and 22B-22C, the exemplary valve cartridge 400 hasseveral discrete components including an upper housing 402, a ball-stem404, a pin 406, a spring 408, a bushing 410, a carrier 412, a movabledisk 414, a fixed disk 416, a base seal 418 and a lower housing 420. Themovable disk 414 and/or the fixed disk 416 can be made of a hardmaterial. For example, the movable disk 414 and/or the fixed disk 416can be made of ceramic. The upper housing 402, for example, can be madeof plastic or metal.

As shown in FIGS. 13A-13C, the upper housing 402 has a domed portion 422and a cylindrical portion 424. A cavity 426 is formed in the upperhousing 402 for receiving the remaining components of the valvecartridge 400. The cavity 426 extends inside the domed portion 422 andthe cylindrical portion 424 of the upper housing 402. The cylindricalportion 424 of the upper housing 402 includes a lower opening 428through which the components can be inserted into the upper housing 402.The dome portion 422 of the upper housing 402 includes an upper opening430 through which a stem portion 432 of the ball-stem 404 extends. Thecavity 426 in the upper housing 402 is wider near the lower opening 428than near the upper opening 430. A portion of the cavity 426 near theupper opening 430 of the upper housing 402 receives a ball portion 434of the ball-stem 404. Accordingly, a first inner surface 436 of theportion of the cavity 426 near the upper opening 430 has a shape thatsubstantially conforms to a shape of the ball portion 434 of theball-stem 404 (see FIGS. 13C and 22B).

A portion of the cavity 426 near the lower opening 428 of the upperhousing 402 receives the bushing 410, the carrier 412, the movable disk414, the fixed disk 416 and the base seal 418 (see FIGS. 22B-22C).Furthermore, as described below, the lower housing 420 interfaces withthe upper housing 402 to form a housing assembly 438 that retains thesecomponents in the cavity 426 of the upper housing 402 (see FIGS.22B-22C).

A portion of the upper housing 402 where the domed portion 422 meets thecylindrical portion 424 forms an installation ledge 440 on an outersurface of the upper housing 402 (see FIGS. 13A-13C and 22A-22C). Theinstallation ledge 440 is substantially below the upper opening 430 ofthe upper housing 402. In one exemplary embodiment, a retention nut(e.g., the retention nut 234 shown in FIG. 11) engages the installationledge 440 to secure the valve cartridge 400 in a valve body (e.g., thevalve body 240 shown in FIG. 11). Furthermore, the upper housing 402 hasone or more keys 442 that each engage a complementary-shaped recess inthe valve body to prevent rotation of the upper housing 402 relative tothe valve body after the valve cartridge 400 is installed. The one ormore keys 442 can have a lobular shape. The upper housing 402 alsoincludes a pair of slots 444 formed on opposing sides of the upperhousing 402 that interface with distal ends of the pin 406 to functionas temperature-limit stops, as described below.

As shown in FIG. 14, the ball-stem 404 is the actuating mechanism forthe valve cartridge 400. The ball-stem 404 includes the ball portion 434and the stern portion 432. The ball portion 434 and the stem portion 432can be discrete components or can be formed integrally. The ball portion434 includes a projection 446 extending from a side of the ball portion446 that is opposite a side of the ball portion 434 from which the stemportion 432 extends. The projection 446 acts as a coupling device forconnecting the ball-stern 404 to the carrier 412, as described below.The ball portion 434 and the projection 446 can be discrete componentsor can be formed integrally.

A bore 448 is formed through a center of the ball portion 434 of theball-stem 404. The bore 448 is orthogonal to the stem portion 432 of theball-stem 404. After the ball-stem 404 is inserted into the cavity 426of the upper housing 402, the pin 406 can be inserted through one of theslots 444 in the upper housing 402 and into the bore 448 of theball-stem 404. In this manner, the pin 406 retains the ball-stem 404 inthe upper housing 402.

As shown in FIGS. 15A-15C, the spring 408 has an annular shape with acentral opening 450. The spring 408 is disposed below the ball portion434 of the ball-stem 404 in the upper housing 402 (see FIGS. 22B-22C).The spring 408 is connected to a second inner surface 452 of the upperhousing 402 (e.g., by or through threading, function fitting, snapfitting, welding), such that the spring 408 also retains the ball-stem404 in the upper housing 402 (see FIGS. 13C and 22C). In one exemplaryembodiment, at least a portion of an outer periphery 454 of the spring408 is welded to the second inner surface 452 of the upper housing 402.

The projection 446 of the ball-stem 404 extends through the centralopening 450 in the spring 408. Some of the ball portion 434 of theball-stem 404 can also extend through the central opening 450 in thespring 408. The spring 408 includes a plurality of elastic flanges 456surrounding the central opening 450. The elastic flanges 456 are spacedapart from one another such that gaps 458 are formed between the elasticflanges 456. The elastic flanges 456 of the spring 408 contact the ballportion 434 of the ball-stem 404 and urge the ball portion 434 of theball-stem 404 against the complementary-shaped first inner surface 436of the upper housing 402. The gaps 458, for example, function to reducethe stress placed on the spring 408 from engaging the ball-stem 404.

As shown in FIGS. 16A-16C, the bushing 410 includes a flat annularportion 460 and a raised annular portion 462. A diameter of the flatannular portion 460 is greater than a diameter of the raised annularportion 462. The bushing 410 is disposed below and can be spaced apartfrom the spring 408 in the cavity 426 of the upper housing 402 (seeFIGS. 22B-22C). An upper surface 464 of the flat annular portion 460 ofthe bushing 410 contacts a third inner surface 466 of the upper housing402, which is located below the installation ledge 440 (see FIGS. 13Cand 22B). A lower surface 468 of the flat annular portion 460 of thebushing 410 rests on an upper surface 470 of a flat portion 472 of thecarrier 412 (see FIGS. 17A-17B, 17D and 22B-22C). Additionally, theraised annular portion 462 of the bushing 410 extends into a portion ofthe cavity 426 of the upper housing 402 immediately above (and adjacentto) the installation ledge 440. The raised annular portion 462 of thebushing 410 is sized to fit closely in that portion of the cavity 426 ofthe upper housing 402 receiving the raised annular portion 462 of thebushing 410. Accordingly, the bushing 410 provides a support surfacebetween the upper housing 402 and the carrier 412.

The bushing 410 has an opening 474 that extends through the flat annularportion 460 and the raised annular portion 462 of the bushing 410. Theraised annular portion 462 can include a first raised annular portion476 and a second raised annular portion 478 with ribs 480 disposedbetween the first and second raised annular portions 476, 478 (see FIG.16C). A raised portion 482 of the carrier 412 extends into the opening474 of the bushing 410 (see FIGS. 17A-17B and 17D). Additionally, acoupling recess 484 is formed in the raised portion 482 of the carrier412. After the carrier 412 is installed in the valve cartridge 400, theraised portion 482 including the coupling recess 484 is positionedwithin the opening 474 of the bushing 410 and surrounded by the bushing410 (see FIGS. 22B-22C).

The coupling recess 484 of the carrier 412 receives the projection 446of the ball-stem 404, thereby connecting the actuating mechanism (i.e.,the ball-stem 404) and the carrier 412 (see FIGS. 22B-22C). Theprojection 446 of the ball-stem 404 can have four sides that contactfour corresponding sides of the coupling recess 484. The projection 446of the ball-stem 404 does not contact a bottom surface of the couplingrecess 484. It will be appreciated that notwithstanding the exemplaryembodiments described herein, the ball-stem 404 can be connected to thecarrier 412 in any suitable manner that allows the ball-stem 404 toimpart translational and angular movement to the carrier 412.

As shown in FIGS. 17A-17D, the carrier 412 includes the flat portion 472and the raised portion 482. A lower surface 486 of the flat portion 472of the carrier 412 includes structure for interfacing with an uppersurface 488 of the movable disk 414, such that the carrier 412 and themovable disk 414 are joined and do not move relative to one another. Inone exemplary embodiment, the lower surface 486 of the carrier 412includes three U-shaped projections 490 that friction fit into threecorresponding U-shaped recesses 492 formed in the upper surface 488 ofthe movable disk 414. The spacing between adjacent U-shaped projections490 (and, thus, the corresponding U-shaped recesses 492) can be variedso that the carrier 412 will only interface with the movable disk 414 inone orientation. Furthermore, as noted above, the carrier 412 alsoincludes the coupling recess 484, which is formed in the raised portion482 of the carrier 412. In this manner, the carrier 412 functions tointerconnect the actuating mechanism (e.g., the ball-stem 404) and thedynamic sealing elements (e.g., the movable disk 414), in the valvecartridge 400.

As shown in FIGS. 18A-18C, the movable disk 414 is a valve member formedas a plate, disk or the like that is movable relative to the upperhousing 402. As noted above, the upper surface 488 of the movable disk414 includes the U-shaped recesses 492. The upper surface 488 issubstantially flat. A lower surface 494 of the movable disk 414 includesa mixing chamber 496 (i.e., a cavity formed in the movable disk 414). Inan alternative exemplary embodiment, the mixing chamber 496 extendsthrough the movable disk 414 (i.e., from the lower surface 494 to theupper surface 488). The lower surface 494 is substantially flat. Thelower surface 494 of the movable disk 414 forms a sealing surface thatcan cover and uncover water inlet apertures 498 and 500 in the fixeddisk 416 to allow only cold water, only hot water or both cold and hotwater to flow through the fixed disk 416. The water flowing through thewater inlet apertures 498 and 500 in the fixed disk 416 enters themixing chamber 496 where the cold and hot water mix prior to beingdischarged through a water outlet aperture 502 in the fixed disk 416.

As shown in FIGS. 19A-19D, the fixed disk 416 is a valve member formedas a plate, disk or the like that is fixed relative to the upper housing402. The fixed disk 416 has an upper surface 504 and a lower surface506. The fixed disk 416 includes structure for interfacing with thelower housing 420 to fix (i.e., prevent rotation) of the fixed disk 416relative to the housing assembly 438 once the valve cartridge 400 isassembled. For example, four notches 508 are formed along a periphery510 of the fixed disk 416. One or more notches 508 engage correspondingprojections 512 formed on the lower housing 420, thereby preventing thefixed disk 416 from rotating relative to the lower housing 420. In oneexemplary embodiment, two notches 508 engage corresponding projections512. By varying the size of and/or the spacing between the notches 508(and, thus, the corresponding projections 512), it is possible to insurethat the fixed disk 416 will interface with the lower housing 420 inonly one orientation. Thus, because the fixed disk 416 is prevented fromrotating relative to the lower housing 420 and the lower housing 420 issecured to the upper housing 402, as described below, the fixed disk 416will not rotate within the housing assembly 438.

The fixed disk 416 includes the water inlet apertures 498 and 500, whichcorrespond to a cold water inlet aperture and a hot water inletaperture, respectively. The fixed disk 416 also includes the wateroutlet aperture 502 through which cold water flowing through the coldwater inlet aperture 498, hot water flowing through the hot water inletaperture 500 or a mixture of the cold and hot water can flow to a wateroutlet passage of the valve body. The cold water inlet aperture 498 andthe hot water inlet aperture 500 of the fixed disk 416 each have walls514 that slope from near the lower surface 506 of the fixed disk 416 tonear the upper surface 504 of the fixed disk 416 to improve the flow ofwater through the fixed disk 416 and into the valve cartridge 400. Thewater outlet aperture 502 of the fixed disk 416 has walls 516 that slopefrom near the upper surface 504 of the fixed disk 416 to near the lowersurface 506 of the fixed disk 416 to improve the flow of water throughthe fixed disk 416 and out of the valve cartridge 400.

As shown in FIGS. 20A-20B, the base seal 418 is a sealing member formedof an elastic material (e.g., rubber). The base seal 418 forms awatertight seal around the cold water inlet aperture 498, the hot waterinlet aperture 500 and the water outlet aperture 502 of the fixed disk416. Like the fixed disk 416, the base seal 418 has a cold water inletaperture 518, a hot water inlet aperture 520 and a water outlet aperture522. In one exemplary embodiment, the water outlet aperture 522 of thebase seal 418 is formed by inserting a member 524 (e.g., a plasticinsert) having the water outlet aperture 522 therein into an opening inthe base seal 418. In another exemplary embodiment, the base seal 418 isformed integrally with the lower housing 420.

The cold water inlet aperture 518, the hot water inlet aperture 520 andthe water outlet aperture 522 are all connected by a hub 526 near thecenter of the base seal 418. Furthermore, the cold water inlet aperture518 is connected to the water outlet aperture 522 by a first connection528; the hot water inlet aperture 520 is connected to the water outletaperture 522 by a second connection 530; and the cold water inletaperture 518 is connected to the hot water inlet aperture 520 by a thirdconnection 532. The joining of the cold water inlet aperture 518 to thewater outlet aperture 522 by the first connection 528 forms a firstspace 534; the joining of the hot water inlet aperture 520 to the wateroutlet aperture 522 by the second connection 530 forms a second space536; and the joining of the cold water inlet aperture 518 to the hotwater inlet aperture 520 by the third connection 532 forms a third space538.

It is important that the apertures 498, 500 and 502 in the fixed disk416 are aligned with the apertures 518, 520 and 522 in the base seal 418when the valve cartridge 400 is assembled. Accordingly, as describedbelow, the hub 526, the first connection 528, the second connection 530,the third connection 532, the first space 534, the second space 536 andthe third space 538 are used to align the base seal 418 in the lowerhousing 420 and, thus, with the fixed disk 418.

As shown in FIGS. 21A-21D and 22B-22C, the lower housing 420 interfaceswith the upper housing 402 to form the housing assembly 438 forretaining the components (e.g., the bushing 410, the carrier 412, themovable disk 414, the fixed disk 416 and the base seal 418) therein(e.g., in the cavity 426 of the upper housing 402) after assembly of thevalve cartridge 400. The lower housing 420, for example, can be made ofplastic or metal. The lower housing 420 can be formed from the samematerial as the upper housing 402.

Furthermore, the lower housing 420 functions as a support member toorient and retain the fixed disk 416 and the base seal 418 prior toassembly of the valve cartridge 400. Similar to the fixed disk 416 andthe base seal 418, the lower housing 420 includes a cold water inletaperture 540, a hot water inlet aperture 542 and a water outlet aperture544 (see FIGS. 21A-21D). As noted above, the lower housing 420 alsoincludes the projections 512. One or more projections 512 can extendabove a sidewall 546 of the lower housing 420. In one exemplaryembodiment, two projections 512 extend above the sidewall 546. One ormore projections 512 can have a height that is substantially the same asa height of the sidewall 546. In one exemplary embodiment, twoprojections 512 have a height that is substantially the same as theheight of the sidewall 546.

One or more projections 512 can fit into corresponding openings 548formed in the upper housing 402 below the keys 442 (see FIGS. 13A-13C).In one exemplary embodiment, three projections 512 fit into threeopenings 548. These projections 512 have a shape that is substantiallythe same as a shape of the keys 442, for example, a lobular shape. Byfitting into the openings 548 below the keys 442, the projections 512also function as part of the keys 442, for example, by engaging thecomplementary-shaped recesses in the valve body.

The size and/or shape of the projections 512 can be varied such that thelower housing 420 will interface with the fixed disk 416 and the upperhousing 402 in only one orientation, thereby insuring that the fixeddisk 416 will be properly oriented relative to the upper housing 402 andthe lower housing 420 when the valve cartridge 400 is assembled. Byengaging the notches 508 in the fixed disk 416, the projections 512 alsoprevent the fixed disk 416 from rotating relative to the lower housing420 (and, thus, the upper housing 402).

The lower housing 420 includes a first recess 550, a second recess 552,a third recess 554 and a fourth recess 556. The lower housing 420 alsoincludes a first projection 558, a second projection 560 and a thirdprojection 562. The hub 526, the first connection 528, the secondconnection 530 and the third connection 532, respectively, of the baseseal 418 fit into the first recess 550, the second recess 552, the thirdrecess 554 and the fourth recess 556, respectively, of the lower housing420. Furthermore, the first projection 558, the second projection 560and the third projection 562, respectively, of the lower housing 420 fitinto the first space 534, the second space 536 and the third space 538,respectively, of the base seal 418. Accordingly, the lower housing 420orients, fixes and retains the base seal 418 in the lower housing 420.

The lower housing 420 also includes a pair of elastic flanges 564 thateach have an angled upper portion 566. The notches 508 in the fixed disk416 allow the elastic flanges 564 to be pressed inward (i.e., toward acentral vertical axis of the valve cartridge 400), such that the angledupper portions 566 can enter the cavity 426 in the upper housing 402.When the angled upper portions 566 are aligned with correspondingopenings 568 formed in the upper housing 402 (see FIGS. 13A-13C), theelastic flanges 564 press outward and the angled upper portions 566 arereceived in the openings 568. In this manner, the lower housing 420(including the fixed disk 416 and the base seal 418 interfacedtherewith) can be secured to the upper housing 402 (see FIGS. 22B-22C).

It should be noted that although the notches 508 of the fixed disk 416interface with the projections 512 of the lower housing 420 to preventthe fixed disk 416 from rotating within the lower housing 420 (and,thus, the upper housing 402), the fixed disk 416 is nonetheless allowedto move axially within the housing assembly 438 (i.e., the upper housing402 and the lower housing 420). In this manner, compression of the baseseal 418 exerts a loading force on the movable disk 414 and the fixeddisk 416. Accordingly, the movable disk 414 and the fixed disk 416 arekept in water-tight engagement with one another, after installation ofthe valve cartridge 400.

The position and the orientation of the movable disk 414 relative to thefixed disk 416 are controlled by the stem portion 432 of the ball-stem404 projecting out of the upper housing 402 through the upper opening430. For example, pivoting the stem portion 432 of the ball-stem 404about a pivot (e.g., the pin 406) changes the position of the movabledisk 414 relative to the fixed disk 416, which changes the flow rate ofthe water. Rotating the stem portion 432 of the ball-stem 404 changesthe orientation of the movable disk 414 relative to the fixed disk 416,which changes the temperature of the water.

An operating member (e.g., the operating member 330 shown in FIG. 11)such as a handle, knob or the like can be connected to the stem portion432 of the ball-stem 404 to facilitate manipulation of the stem portion432 by a user. Accordingly, after the valve cartridge 400 is installedin the valve body, the user can manipulate the operating member whichmoves the stem portion 432 of the ball-stem 404 to change the positionand/or orientation of the movable disk 414 relative to the fixed disk416, thereby controlling the flow rate and temperature of the waterflowing through the valve cartridge 400 and out a plumbing fixture(e.g., the plumbing fixture 332 shown in FIG. 11).

Pivoting of the stem portion 432 of the ball-stem 404 about the pin 406can be limited by the stem portion 432 contacting opposing surfaces ofthe upper opening 430 of the upper housing 402. Thus, the stem portion432 of the ball-stem 404 contacts a first surface 570 of the upperopening 430 of the upper housing 402 when the valve cartridge 400 is ina fully closed position corresponding to a flow rate of zero (see FIG.22C). The stem portion 432 of the ball-stem 404 contacts a secondsurface 572 of the upper opening 430 of the upper housing 402 when thevalve cartridge 400 is in a fully open position corresponding to amaximum flow rate.

Rotation of the stem portion 432 of the ball-stem 404 can be limited bythe distal ends of the pin 406 contacting end portions 574 of the slots444 (see FIG. 22A). Accordingly, the length of the slots 444, whichfunction as temperature limit stops, define the range of temperaturesfor which the valve cartridge 400 can deliver the water.

The valve cartridge 400 has a low point of contact (i.e., theinstallation ledge 440 formed on the upper housing 402) on which theretention nut bears down. The installation ledge 440 is a circular ledgethat extends around the upper housing 402 where the domed portion 422 ofthe upper housing 402 meets the cylindrical portion 424 of the upperhousing 402. The installation ledge 440 is the highest point on thehousing assembly 438 that contacts the retention nut.

In an exemplary embodiment of the exemplary valve cartridge 400, one ormore installation ledges (e.g., the installation ledge 440 are formed onthe housing assembly 438 of the valve cartridge 400. The highest of theinstallation ledges is a low point of contact on the housing assembly438 for installing the valve cartridge 400 in the valve body.

A ratio R₁ of a height h₁ of the highest installation ledge on thehousing assembly 438 to a largest outer diameter d of the housingassembly 438 is less than or equal to 0.53 (see FIG. 22C), which can beexpressed as h₁/d≦0.53. In another exemplary embodiment of the exemplaryvalve cartridge 400, the ratio R₁ of the height h₁ to the largest outerdiameter d is less than or equal to 0.52. In still another exemplaryembodiment, the ratio R₁ of the height h₁ to the largest outer diameterd is approximately equal to 0.53.

According to still another exemplary embodiment of the exemplary valvecartridge 400, a ratio R₂ of the height h₁ to a height h₂ of the housingassembly 438 is less than or equal to 0.49 (see FIG. 22C), which can beexpressed as h₁/h₂≦0.49 In another exemplary embodiment, the ratio R₂ ofthe height h₁ to the height h₂ is less than or equal to 0.47. In stillanother exemplary embodiment, the ratio R₂ of the height h₁ to theheight h₂ is approximately equal to 0.48.

According to yet another exemplary embodiment of the exemplary valvecartridge 400, a ratio R₃ of the height h₁ to a height h₃ of the pin 406(e.g., from a bottom of the housing assembly 438 to a centerline of thepin 406) is less than or equal to 0.67 (see FIG. 22C), which can beexpressed as h₁/h₃≦0.67. In another exemplary embodiment, ratio R₃ ofthe height h₁ to the height h₃ is less than or equal to 0.65. In stillanother exemplary embodiment, ratio R₃ of the height h₁ to the height h₁is approximately equal to 0.66.

According to another exemplary embodiment of the exemplary valvecartridge 400, the highest installation ledge on the housing assembly438 is below an actuating mechanism (e.g., the ball-stem 404) of thevalve cartridge 400 (see FIG. 22C). In still another exemplaryembodiment of the exemplary valve cartridge 400, the highestinstallation ledge on the housing assembly 438 is below the actuatingmechanism and above a mixing chamber (e.g., the mixing chamber 496) ofthe valve cartridge 400. In yet another exemplary embodiment of theexemplary valve cartridge 400, the highest installation ledge on thehousing assembly 438 is below the actuating mechanism and above a fixeddisk (e.g., the fixed disk 416) of the valve cartridge 400.

According to an exemplary embodiment of the exemplary valve cartridge400, the height h₁ of the highest installation ledge on the housingassembly 438 is between 0.641 and 0.651 inches. In one exemplaryembodiment, the height h₁ of the highest installation ledge on thehousing assembly 438 is approximately equal to 0.646 inches.

According to another exemplary embodiment of the exemplary valvecartridge 400, the height h₂ of the housing assembly 438 is between1.339 and 1.369 inches. In one exemplary embodiment, the height h₂ ofthe housing assembly 438 is approximately equal to 1.354 inches.

According to still another exemplary embodiment of the exemplary valvecartridge 400, the height h₃ of the pin 406 is between 0.973 and 0.993inches. In one exemplary embodiment, the height h₃ of the pin 406 isapproximately equal to 0.983 inches.

According to yet another exemplary embodiment of the exemplary valvecartridge 400, the outer diameter d of the housing assembly 438 isbetween 1.220 and 1.228 inches. In one exemplary embodiment, the outerdiameter d of the housing assembly 438 is approximately equal to 1.224inches.

As illustrated by way of the exemplary embodiments described herein, theinstallation ledge 440 (as a highest installation ledge on the housingassembly 438) is a low point of contact on the housing assembly 438 onwhich the retention nut can bear down during installation of the valvecartridge 400 in the valve body. Accordingly, the valve cartridge 400has a compact structure that provides increased flexibility in thedesign of plumbing fixtures (e.g., the plumbing fixture 332 shown inFIG. 11) that will accommodate the valve cartridge 400. Furthermore, thelow installation ledge 440 allows less material to be used in formingthe valve body, since sidewalls of the valve body can be made shorter(see FIG. 11). As a result, the low installation ledge 440 provides acost savings.

The above description of specific embodiments has been given by way ofexample. From the disclosure given, those skilled in the art will notonly understand the general inventive concept and its attendantadvantages, but will also find apparent various changes andmodifications to the structures and methods disclosed. It is sought,therefore, to cover all such changes and modifications as fall withinthe spirit and scope of the general inventive concept, as definedherein, and equivalents thereof.

The invention claimed is:
 1. A valve cartridge for controlling a flowrate of a fluid and operable to be secured in a valve body by aretaining member, the valve cartridge comprising: a housing having adomed portion proximate a top surface of the housing and a cylindricalportion proximate a bottom surface of the housing; an actuatingmechanism; and a fluid control member, wherein the fluid control memberis disposed in the cylindrical portion of the housing, wherein a firstportion of the actuating mechanism extends through an opening in the topsurface of the housing and a second portion of the actuating mechanismis disposed in the domed portion of the housing, wherein movement of theactuating mechanism moves the fluid control member to vary the flow rateof the fluid, wherein an installation ledge is formed where the domedportion of the housing meets the cylindrical portion of the housing, theinstallation ledge being the highest point on the housing for contactingthe retaining member, a height of the installation ledge being theheight from the bottom surface of the housing to the installation ledge,and wherein the installation ledge is closer to the bottom surface ofthe housing than the top surface of the housing.
 2. The valve cartridgeof claim 1, wherein a ratio of the height of the installation ledge onthe housing to a largest outer diameter of the housing is less than orequal to 0.50.
 3. The valve cartridge of claim 2, wherein the height ofthe installation ledge is between 0.486 and 0.494 inches.
 4. The valvecartridge of claim 1, wherein a ratio of the height of the installationledge on the housing to a height of the housing between the top surfaceand the bottom surface is less than or equal to 0.39.
 5. The valvecartridge of claim 4, wherein the height of the installation ledge isbetween 0.486 and 0.494 inches.
 6. The valve cartridge of claim 1,wherein a pin secures the actuating mechanism in the housing so that theactuating mechanism is operable to pivot about the pin, and wherein aratio of the height of the installation ledge on the housing to a heightof a center of the pin from the bottom surface of the housing is lessthan or equal to 0.55.
 7. The valve cartridge of claim 6, wherein theheight of the installation ledge is between 0.486 and 0.494 inches. 8.The valve cartridge of claim 1, wherein a ratio of the height of theinstallation ledge on the housing to a largest outer diameter of thehousing is less than or equal to 0.53.
 9. The valve cartridge of claim8, wherein the height of the installation ledge is between 0.641 and0.651 inches.
 10. The valve cartridge of claim 1, wherein a ratio of theheight of the installation ledge on the housing to a height of thehousing between the top surface and the bottom surface is less than orequal to 0.49.
 11. The valve cartridge of claim 10, wherein the heightof the installation ledge is between 0.641 and 0.651 inches.
 12. Thevalve cartridge of claim 1, wherein a pin secures the actuatingmechanism in the housing so that the actuating mechanism is operable topivot about the pin, and wherein a ratio of the height of theinstallation ledge on the housing to a height of a center of the pinfrom the bottom surface of the housing is less than or equal to 0.67.13. The valve cartridge of claim 12, wherein the height of theinstallation ledge is between 0.641 and 0.651 inches.
 14. The valvecartridge of claim 1, wherein the installation ledge is located below alowermost portion of the actuating mechanism.
 15. The valve cartridge ofclaim 14, wherein the installation ledge is located above the fluidcontrol member.
 16. The valve cartridge of claim 1, wherein theinstallation ledge extends around an outer circumference of the housing.17. The valve cartridge of claim 1, wherein the housing is a unitarybody.
 18. The valve cartridge of claim 1, wherein the second portion ofthe actuating mechanism is spherical.
 19. A valve cartridge forcontrolling a flow rate and a mixture ratio of cold water and hot waterand operable to be secured in a valve body by a retaining member, thevalve cartridge comprising: a housing having a domed portion proximate atop surface of the housing and a cylindrical portion proximate a bottomsurface of the housing; an actuating mechanism; a movable controlmember; and a fixed control member, wherein at least one of the movablecontrol member and the fixed control member are disposed in thecylindrical portion of the housing, wherein a first portion of theactuating mechanism extends through an opening in the top surface of thehousing and a second portion of the actuating mechanism is disposed inthe domed portion of the housing, wherein movement of the actuatingmechanism about a first axis is operable to move the movable controlmember relative to the fixed control member to vary the flow rate of atleast one of the cold water and the hot water, wherein movement of theactuating mechanism about a second axis is operable to move the movablecontrol member relative to the fixed control member to vary the mixtureratio of the cold water and the hot water, wherein an installation ledgeis formed where the domed portion of the housing meets the cylindricalportion of the housing, the installation ledge being the highest pointon the housing for contacting the retaining member, a height of theinstallation ledge being the height from the bottom surface of thehousing to the installation ledge, and wherein the installation ledge iscloser to the bottom surface of the housing than the top surface of thehousing.
 20. The valve cartridge of claim 19, wherein the installationledge is located below a lowermost portion of the actuating mechanism.21. The valve cartridge of claim 20, wherein the installation ledge isabove the fixed control member.
 22. The valve cartridge of claim 20,further comprising a mixing chamber within the housing for mixing thecold water and the hot water, and wherein the installation ledge islocated above the mixing chamber.
 23. The valve cartridge of claim 19,wherein the installation ledge extends around an outer circumference ofthe housing.
 24. The valve cartridge of claim 19, wherein the housing isa unitary body.
 25. The valve cartridge of claim 19, wherein the secondportion of the actuating mechanism is spherical.